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Home >> Suzuki >> 2005 >> XL-7 EX, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Manual Transmission) >> H25 Engine Model >> Repair Instructions >> Manual Transmission Rear Case Disassembly and Assembly >> Assembly
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Manual Transmission Rear Case Disassembly and Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Check that interlock cam component (1) moves smoothly in both turning direction and sliding direction.
    Fig 1: Checking Interlock Cam Component
    G04100343Courtesy of SUZUKI OF AMERICA CORP.
  2. Insert interlock cam component (1) to rear case.
    Fig 2: Inserting Interlock Cam Component To Rear Case
    G04100344Courtesy of SUZUKI OF AMERICA CORP.
  3. Set interlock cam component (1) as shown in the figure and drive pin by using special tool.

    Special tool 

    (A): 09922-85811 

    Fig 3: Setting Interlock Cam Component
    G04100345Courtesy of SUZUKI OF AMERICA CORP.
  4. Apply thread lock cement to thread of interlock cam plug (1) and tighten it to specification.

    "A": Thread lock cement 99000-32020 

    Tightening torque 

    Interlock cam plug (a): 19 N.m (1.9 kg-m, 14.0 lb-ft) 

    Fig 4: Applying Thread Lock Cement To Thread Of Interlock Cam Plug
    G04100346Courtesy of SUZUKI OF AMERICA CORP.
  5. Install oil seal to rear case so that end surface of oil seal becomes flush with that case.

    Apply grease to oil seal lip.

    : Grease 99000-25010 

    Special tool 

    (B): 09913-75510 

    Fig 5: Installing Oil Seal To Rear Case
    G04100347Courtesy of SUZUKI OF AMERICA CORP.
  6. Install countershaft gutter (2) to transmission rear case (1).
Fig 6: Installing Countershaft Gutter To Transmission Rear Case
G04100348Courtesy of SUZUKI OF AMERICA CORP.